Methane and emissions reduction system

Abstract

A system that can eliminate engine combustion emissions in addition to raw and fugitive methane emissions associated with a gas compressor package. The system may comprise an air system for starting and instrumentation air supply; electrically operated engine pre/post-lube pump, compressor pre-lube pump, and cooler louver actuators; compressor distance piece and pressure packing recovery system; blow-down recovery system; engine crankcase vent recovery system; a methane leak detection system; and an overall remote monitoring system.

The invention claimed is: 
     
         1 . A system to reduce gas emissions from a compressor package, the system comprising:
 a. a reciprocating compressor and an engine that drives the reciprocating compressor, wherein at least one of the reciprocating compressor and the engine produce gas emissions;   b. a blowdown recovery system comprising an external suction line in fluid communication with said reciprocating compressor and an external tank battery such that gas emissions produced by the reciprocating compressor during blowdown events are directed through said external suction line and recycled through the compressor package or directed to the external tank battery; and   c. a monitoring system coupled to said blowdown recovery system, said monitoring system configured to monitor key performance indicators and implement an algorithm to identify gas emissions or leaks from at least one of said reciprocating compressor and said engine, wherein said monitoring system provides real time feedback to actuate compressor package adjustments based on said identified gas emissions or leaks.   
     
     
         2 . The system of  claim 1 , further comprising a compressor packing recovery system, wherein said reciprocating compressor comprises packing vents and said compressor packing recovery system captures and directs process gas generated by said packing vents. 
     
     
         3 . The system of  claim 1 , further comprising a gas emissions detection system that detects gas emissions emitted from at least one of said reciprocating compressor and said engine, wherein said gas emissions detection system is coupled to said monitoring system. 
     
     
         4 . The system of  claim 1 , further comprising an engine pre/post-lube pump and a compressor pre-lube pump, wherein said engine pre/post-lube pump and compressor pre-lube pump are configured to circulate oil and build up oil pressure when said engine is actuated. 
     
     
         5 . The system of  claim 1 , wherein said reciprocating compressor further comprises a plurality of cooler louvers and at least one cooler louver actuator. 
     
     
         6 . The system of  claim 3 , wherein the gas emissions detection system is configured to trigger at least one event when an amount of detected gas emissions exceeds a predetermined limit, and wherein said at least one event is selected from turning said engine off, sounding an alarm, and providing an alert to an operator. 
     
     
         7 . The system of  claim 6 , wherein the predetermined limit is set based on one or more working parameters of the reciprocating compressor. 
     
     
         8 . The system of  claim 6 , wherein the gas emissions detection system is configured to trigger the at least one event in order to prevent excess leakage of gas. 
     
     
         9 . A system to reduce emissions from a compressor package, the system comprising:
 a. a reciprocating compressor with an engine system that drives the reciprocating compressor, wherein at least one of the reciprocating compressor and the engine system emit methane;   b. an air system comprising an air compressor, said air compressor configured to generate compressed air, wherein at least a portion of said compressed air is routed to an air dryer and then to a plurality of instrumentation so that said plurality of instrumentation is powered by said portion of said compressed air; and   c. a monitoring system that monitors key performance indicators and implements an algorithm to identify system emissions or leaks in said compressor package, wherein at least said air system is coupled to said monitoring system, and wherein said monitoring system is configured to provide real time feedback to instruct compressor package adjustments based on said identified system emissions or leaks.   
     
     
         10 . The system of  claim 9 , further comprising at least one scrubber and wherein said plurality of instrumentation comprises a plurality of scrubber level controls. 
     
     
         11 . The system of  claim 9 , wherein said monitoring system is a remote monitoring system. 
     
     
         12 . The system of  claim 9 , wherein the monitoring system is in communication with a thermal imaging camera. 
     
     
         13 . The system of  claim 9 , further comprising a methane detection system that detects the methane emitted from the at least one of said reciprocating compressor and said engine system. 
     
     
         14 . The system of  claim 13 , wherein said methane detection system monitors emissions of methane and volatile organic compounds and detects fugitive emissions from said compressor package in real time. 
     
     
         15 . The system of  claim 13 , wherein said methane detection system is coupled to said monitoring system. 
     
     
         16 . A retrofit kit to adapt a compressor package comprising an engine system that drives a reciprocating compressor, wherein said compressor package emits exhaust and fugitive emissions, the retrofit kit comprising:
 a. a blowdown recovery system comprising an external suction line in fluid communication with said compressor package and an external tank battery such that exhaust and fugitive emissions emitted by said compressor package during blowdown events are directed through said external suction line and recycled through said compressor package or directed to the external tank battery; and   b. a monitoring system coupled to said blowdown recovery system, said monitoring system configured to monitor key performance indicators and implement an algorithm to identify fugitive emissions or leaks from said compressor package, wherein said monitoring system provides real time feedback to actuate compressor package adjustments based on said identified fugitive emissions or leaks.   
     
     
         17 . The retrofit kit of  claim 16 , further comprising vents and a pressure packing vent recovery system in communication with said vents and a pressure tank, wherein the pressure packing vent recovery system routes exhaust departing the vents to the pressure tank. 
     
     
         18 . The retrofit kit of  claim 16 , wherein said compressor package adjustments comprise actuating a blowdown of said compressor package and wherein said blowdown of said compressor package is actuated when said monitoring system detects said fugitive emissions at a predetermined level.